Battery connector device for a battery jump starting device

ABSTRACT

An enhanced conductivity battery device for use in a battery jump starting device. The enhanced conductivity device providing enhanced conductivity from the enhanced conductivity device to a battery being jump started.

FIELD

A portable battery connector device, for example, a battery connectorarrangement or assembly for a battery jump starting device, inparticular a portable vehicle jump starting apparatus, configured forenhancing the conductivity between the battery of the jump startingapparatus and a battery being charged.

BACKGROUND

The exists a portable vehicle battery jump start apparatus as disclosedin U.S. Pat. No. 9,007,015 to Nook et al. The apparatus utilizes alithium ion battery pack. In this type of apparatus, there exists a needto maximize conductivity from the battery pack to the vehicle battery ofthe vehicle being jump started.

For successful car jump-starts, there are two main factors dictating theresults. The first factor is the amount of power provided by the lithiumion battery pack, and the second factor is the maximum conductivity. Youneed both factors to have the best chance to jump-start big engines. Onefactor without the other factor is not enough.

SUMMARY

The presently described subject matter is directed to a battery device,for example, a battery connector, battery connector arrangement, orbattery conductor assembly for use in a device for jump starting avehicle, and a device for jump starting a vehicle comprising the batteryconnector device.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having at leastone battery conductor connected to a terminal of the battery.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having at leastone battery conductor or cable connected to a battery tab of thebattery.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positiveconductor and a negative conductor connected to the battery.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positiveconductor plate and/or a negative conductor plate connected to thebattery.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positiveconductor plate and/or a negative conductor plate connected to thebattery, and a positive cable connected to the positive conductor plateand/or a negative cable connected to the negative conductor plate.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positivebattery conductor connected to a positive terminal of the battery and/ora negative battery conductor connected to a negative terminal of thebattery.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positivebattery conductor connected to a positive terminal contact of thebattery and/or a negative battery conductor connected to a negativeterminal contact of the battery, the battery conductors being solderedto the respective terminals of the battery.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positivebattery conductor connected to a positive terminal of the battery and/ora negative battery conductor connected to a negative terminal contact ofthe battery, and a relay connected to one of the battery conductors ofthe battery.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positivebattery conductor connected to a positive terminal contact of thebattery and/or a negative battery conductor connected to a negativeterminal contact of the battery; and a relay connected to the negativebattery conductor.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positivebattery conductor connected to a positive terminal contact of thebattery and/or a negative battery conductor connected to a negativeterminal contact of the battery; and a relay connected to the negativebattery conductor.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positivebattery conductor connected to a positive terminal contact of thebattery and/or a negative battery conductor connected to a negativeterminal contact of the battery; and multiple relays connected to thenegative battery conductor.

The presently described subject matter is directed to a batteryconnector device comprising or consisting of a battery having a positivebattery conductor connected to a positive terminal contact of thebattery and/or a negative battery conductor connected to a negativeterminal contact of the battery, and a positive cable connected to thepositive battery conductor.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front view of the battery jump starting device with theclamps un-deployed.

FIG. 2 is a rear perspective view of the battery jump starting deviceshown in FIG. 1.

FIG. 3 is an end perspective view of the battery jump starting deviceshown in FIGS. 1 and 2.

FIG. 4 is a front perspective view of the battery jump starting deviceshown in FIG. 1, however, with the clamps deployed.

FIG. 5 is a front perspective view of a battery connector devicecontained within the battery jump starting device shown in FIG. 1,however, with the negative cable not yet installed.

FIG. 6 is a top planer view of the battery connector device shown inFIG. 5.

FIG. 7 is a side elevational view of the battery connector device shownin FIG. 5.

FIG. 8 is an end elevational view of the battery connector device shownin FIG. 5.

FIG. 9 is a perspective view of the battery connector device shown inFIG. 5 however, with the negative cable connected to the batteryconnector device.

FIG. 10 is a view perspective view of the battery connector device shownin FIG. 5, however, with a diode connector installed on the positivecable.

FIG. 11 is a perspective view of the battery connector device connectedto other components or parts of the battery jump starting device.

FIG. 12 is a perspective view of the battery assembly of the batteryconnector device shown in FIG. 5.

FIG. 13 is a front perspective view of another battery connector devicefor the battery jump starting device.

FIG. 14 is a detailed view of the positive cable connection with therelay printed circuit board prior to being soldered thereto.

FIG. 15 is a detailed view of the positive cable connection with therelay printed circuit board after being soldered thereto.

FIG. 16 is a front perspective view of the battery assembly of thebattery connector device shown in FIG. 13.

FIG. 17 is a partial top planar view of the battery assembly shown inFIG. 16, however, with the positive terminal conductor sheet in anunwound condition.

FIG. 18 is a partial top planer view of the positive terminal conductorof the battery assembly shown in FIG. 16.

FIG. 19 is an end perspective view of the positive terminal conductorpartially wound around the end of the positive cable.

FIG. 20 is an end perspective view of the positive terminal conductorfully wound around the end of the positive cable.

FIG. 21 is a side perspective view of the positive terminal conductorfully wound around and soldered to the end of the positive cable.

FIG. 22 is an opposite end perspective view of the positive terminalconductor fully wound around and soldered to the end of the positivecable.

FIG. 23 is a perspective view of the diode connector between sections ofthe positive cable.

FIG. 24 is a perspective view of a Schottky Diode used in the diodeconnector.

FIG. 25 is a perspective view of the diode connector insulated with ashrink wrap sleeve.

FIG. 27 is a graphical illustration showing a load test of the batteryconnection shown in FIGS. 5-10.

FIG. 28 is a graphical illustration showing a load test of the batteryconnection shown in FIGS. 13-25.

FIG. 29 is a front view of a further battery connector device for thebattery jump starting device.

FIG. 30 is a front view of the battery connector device comprising aplurality of battery cells, separate tab, and conductors (e.g. plateconductors) prior to assembly.

FIG. 31 is a front view of the battery connector device comprisingbattery cells being prepared with separate tabs for lengthening thetabs.

FIG. 32 is a front view of the battery connector device comprising theplurality of battery cells, separate tab, and conductors shown in FIG.30, after assembly.

FIG. 33 is a perspective view showing the battery connector devicecomprising the battery cell assembly shown in FIG. 32, after folding thebattery cells.

FIG. 34 is an end perspective view of the battery connector deviceshowing the separate tab being wrapped or wound around an exposed end ofthe positive cable, and soldered together.

FIG. 35 is an opposite end perspective view of the battery connectordevice showing a negative battery tab wrapped around the negativeterminal conductor plate and welded and/or soldered together.

FIG. 36 is a perspective view of the battery connector device showingthe flat separate tab connected to the battery and extending outwardlyprior to connection to the positive cable.

FIG. 37 is a side view of the temperature sensor assembly with wires andconnector.

FIG. 38 is a perspective view of the diode circuit board assembledconnected inline or spliced into the positive cable.

DETAILED DESCRIPTION

A battery jump starter device 10 is shown in FIGS. 1 and 2. The batteryjump starting device 10 comprises a casing 12 having a display 14provided with an arrangement of light emitting diodes (LEDs) 16.

The battery jump starting device 10 further comprises a positive cable18 having a positive clamp 20 and a negative cable 22 having a negativeclamp 24. The positive cable 18 and negative cable 22 pass throughopenings 12 a, 12 b, respectively, in the casing 12.

The clamps 20, 24 are stowed away or docked in an un-deployed mode byclamping each to a respective side posts 26 extending outwardly onopposite sides of the casing 12, as shown in FIG. 1. The side posts 26are shown in FIG. 2. The clamps 20, 24 are docked when the battery jumpstarter device 10 is in non-use, and then unclamped from the side post26 during use.

The battery jump starting device 10 is configured to jump start avehicle battery. For example, the battery jump starting device 10 can bethe PORTABLE VEHICLE JUMP START APPARATUS WITH SAFETY PROTECTIONdisclosed in U.S. Pat. No. 9,007,015, which is fully incorporated hereinby reference, or a device or apparatus similar thereto.

The battery jump starting device 10 comprises electrical components orparts located inside the casing 12. For example, the battery jumpstarting device 10 comprises a battery connector device 100 shown inFIGS. 3-9.

The battery connector device 100 comprises a battery assembly 110 havinga battery 112. For example, the battery 112 is a lithium ionrechargeable type battery. The battery connector device 100 isconfigured to maximize conductivity from the battery 112 to the cables18, 22 and clamps 20, 24 of the battery jump starter device 10. Thebattery 112 comprises a battery casing 112 a, for example, arectangular-shaped battery casing 112 a.

The battery 112 comprises a positive tab at one end (e.g. width) of thebattery 112, and a negative terminal tab at an opposite end (e.g. width)of the battery 112. For example, the battery 112 comprises one or morebattery cells each having a positive and negative tab. For example, thepositive tab from one battery cell is located at the one end of thebattery 112 and the negative tab from one battery cell is located at theopposite end of the battery 112. A positive terminal conductor plate 114is connected (e.g. soldered, welded, or sonically welded) at the one endof the battery 112 to the positive tab (i.e. contact) of the battery112. The positive terminal conductor plate 114 extends along the one end(e.g. width) of the battery 112.

The positive cable 18 can be connected (e.g. directly connected bysoldering) to the positive terminal conductor plate 114 and/or thepositive tab of the battery 112. For example, the positive terminalconductor bar 114 can be provided with a conductive loop 116 wrappingaround (e.g. entirely wrapping around) and connected (e.g. crimpedand/or soldered) to an exposed end 18 a of the positive cable 18. Forexample, the positive terminal conductor plate 114 is made from heavygauge copper sheet (e.g. machined, cut, or stamped therefrom).

As shown in FIGS. 5 and 6, the positive terminal conductor sheet 114 canbe configured (e.g. bent) to wrap around one of the square-shapedcorners of the rectangular-shaped casing 112 a of the battery 112 (e.g.L-shaped). The L-shaped positive terminal conductor sheet 114 can extendalong an end of the battery 112 and along at least a portion of the sideof the battery 112, as shown in FIG. 5.

The positive terminal conductor plate 114 can also be mechanicallycoupled and/or adhered to the outer surface of the battery casing 112 ato provide additional support and stability thereof (e.g. assembled tosurvive mechanical shock when drop testing the battery jump starterdevice 10). For example, the positive terminal conductor bar 114 can bemechanically connected to the battery casing 112 by adhesive (e.g.silicon adhesive), double sided tape, double sided foam tape, insulatedplastic or ceramic connector with snap fit connection and/or adhesiveconnection, and/or the battery casing 112 can be formed (e.g. molded) tomechanically connect (e.g. snap fit or interference connection) with thepositive terminal conductor plate 114.

The positive cable 18 can be a single piece of wire or a cable (e.g.twisted or braided wires) extending from the battery 110 to the positiveclamp 20. Specifically, one end of the positive cable 18 is connected tothe positive terminal conductor plate 114 connected to the battery 18,and the opposite end of the positive cable 18 is connected to thepositive clamp 20.

More specifically, the positive cable 18 can comprise a flexible or bentcable portion 118 for changing the direction of the positive cable 18within the casing 12. The positive cable 18 can be fitted with aflexible outer sleeve portion 120 transitioning into a flexible innersleeve portion 122 to flexibly accommodate the positive cable 18 passingthrough the casing 12. The flexible outer sleeve portion 120 isexternally located relative to the casing 12 of the battery jump starterdevice 10, and the flexible inner sleeve portion 122 is internallylocated relative to the casing 12 of the battery jump starter device 10.

The flexible outer sleeve portion 120 is configured to reinforce theconnection between the positive cable 18 and the casing 12 of thebattery jump starter device while remaining flexible. For example, theflexible outer sleeve portion 120 is provided with one or more grooves124 (e.g. three (3) shown in FIG. 5) exposing portions of the positivecable 18. The one or more grooves 124 act as hinges to ease bending ofthe positive cable 18 within the flexible outer sleeve portion 120.

The flexible sleeve 120 comprises an outer flange 124 spaced apart (e.g.a small distance equal to about a wall thickness of the casing 12 of thebattery jump starter device 10) from an in inner flange 126. The flanges124, 126 further anchor the positive cable 18 to the casing 12 of thebattery jump starter device 10.

The flexible sleeve 120 comprises a sleeve portion 128 (FIG. 6)connecting together the outer flange 124 and inner flange 126. Forexample, the flexible outer sleeve portion 120 is molded or applied ontoand around the positive cable 18 as a single unit (e.g. the flexiblesleeve 120 is molded onto a portion of the positive cable 18 insertedwithin the mold during the molding process). Alternatively, the flexiblesleeve 120 is made (e.g. molded) separately, and then installed orassembled onto a portion of the positive cable 18.

The positive cable 18 comprises an inner conductor 18 b (e.g. singlewire conductor, twisted wires, or braided wires) disposed within anouter insulating sheath 18 c (e.g. extruded plastic sheath). The innerconductor 18 b, for example, can be a solid wire conductor or a multistrand metal wire conductor comprising bundle of wires 18 d. The innerwire can be made of copper or aluminum. The flexible sleeve 120 can beapplied (e.g. molded or installed or assembled) onto and surrounding theouter insulating sheath 18 c of the positive cable 18.

The battery connector device 100 further comprises a negative terminalconductor plate 130 connected (e.g. soldered, welded, or sonicallywelded) at an opposite end of the battery 112 to the negative tab (i.e.contact) of the battery 112. The negative terminal conductor plate 130can extend along the opposite end of the battery 112.

The other end of the negative terminal conductor plate 130 is providedwith a negative terminal conductor plate connector portion 132, as shownin FIGS. 5 and 6.

The negative terminal conductor plate 130 can be configured to wraparound one of the corners of the rectangular-shaped battery 112 (e.g.L-shaped). The L-shaped negative terminal conductor plate 130 can extendalong an end of the battery 112 and along at least a portion of the sideof the battery 112, as shown in FIGS. 5 and 6.

The negative terminal conductor bar 130 can also be mechanically coupledand/or adhered to the outer surface of the battery casing 112 a toprovide additional support and stability thereof (e.g. to survivemechanical shock when drop testing the battery jump starter device 10).For example, the negative terminal conductor bar 114 can be mechanicallyconnected to the battery casing 112 a by adhesive (e.g. siliconadhesive), double sided tape, double sided foam tape, insulating plasticor ceramic connector with snap fit connection and/or adhesiveconnection, and/or the battery casing 112 can be formed (e.g. molded) tomechanically connect (e.g. snap fit or interference connection) with thepositive terminal conductor plate 114.

The battery connector device 100 further comprises a smart switchbattery interface 134. The smart switch battery interface 134 comprisesa relay printed circuit board (PCB) 136 having a first circuit boardconductor bar 138 spaced apart from a second circuit board conductor bar140 located on one side of the circuit board 136, as shown in FIGS. 5and 6.

A pair of relays 142 are mounted on an opposite side of the circuitboard 136. The relays 142 include relay anchoring pins 142 a located inthrough holes 136 a in the relay printed circuit board 136 (FIGS. 5 and7). The relays 142 further comprise relay connector pins 142 b extendingthrough the through holes 136 b provided in the circuit board 136 andslots 138 a provided in the first conductor bar 138. The relays 142 evenfurther comprise relay connector pins 142 c located in the through holes136 c provided in the circuit board 136 and through holes 140 a providedin the second conductor bar 140. The relay anchoring pins 136 a aresoldered in place to mechanically connect the relays 142 to the circuitboard 136. The relay connecting pins 142 b and 142 c are soldered inplace to mechanically and electrically connect the relays 142,respectively to the circuit board conductor plates 138, 140.

The through holes 136 a in the circuit board 136 are rectangular-shaped(FIGS. 5 and 7) and accommodate the relay anchoring pins 142 a.Specifically, a base portion of the relay anchoring pins 142 a arerectangular-shaped with square-shaped ends. The square-shaped ends aredimensionally less wide verses the base portions creating transverseedges oriented flush with the outer surface of the circuit board 136.When solder is applied to the exposed ends of the relay anchoring pins142 a, the solder connects to the sides of the square-shaped ends andtransverse edges to anchor and lock the relay anchoring pins to thecircuit board 136.

The slots 132 a provided in negative terminal conductor bar connectorportion 132 are rectangular-shaped and the through holes 138 a in thefirst circuit board conductor bar 138 (FIG. 3) are T-shaped toaccommodate the three (3) horizontally oriented relay connector pins 142b, as shown in FIG. 3. The ends of the relay connector pins 142 b areshown flush with the outer surface of the negative terminal conductorbar connector portion 132. When solder is applied to the exposed ends ofthe relay connector pins 142 b, the solder fills in the slots 132 a inthe negative terminal conductor bar connector portion 132 and thethrough holes 138 a of the first circuit board conductor bar 138, andconnects the sides of the connector pins 142 b with inner edges of theslots 132 a and through holes 138 a to anchoring the relays 142 to thecircuit board 136 and negative terminal conductor bar connector portion132. This applied solder also electrically connects the negativeterminal conductor bar connector portion 132 to the first circuit boardconductor bar 138.

The through holes 140 a provided in the second circuit board conductorbar 140 are T-shaped to accommodate the three (3) vertically orientedrelay connecting pins 142 c, as shown in FIG. 3. The relay connectorprongs 140 a extend outwardly from the outer surface of the circuitboard 136 to connect with the exposed conductor end 144 a of thenegative cable 144, and shown in FIG. 7. When solder is applied to theexposed conductor end 144 a and the ends of the relay connector prongs140 a, the solder fills in the T-shaped slot and electrically connectsthe relay connector prongs 140 a, second circuit board conductor 140;and exposed conductor end 144 a of the negative cable 144.

The negative terminal conductor bar connector portion 132 of thenegative terminal conductor bar 130 is connected (e.g. by soldering) tothe first circuit board conductor bar 138 of the circuit board 136. Theexposed conductor end 22 a (i.e. with the insulating sheath removed) ofthe negative cable 22 is connected (e.g. by soldering) to the secondcircuit board conductor bar 140, as shown in FIG. 9.

The battery connector device 100 can be modified by providing thepositive cable 18 with a diode connection 150, as shown in FIG. 10. Forexample, a diode connection is installed (e.g. spliced) into thepositive cable 18. The diode connection 150 comprises a diode printedcircuit board (PCB) 152 provided with a set of back-charge diodes 154(e.g. Schottky Diodes) located on one side thereof, and a conductor bar156 provided on an opposite side of the circuit board 152.

Assembly

The battery jump starting device 10 comprises the casing 12 having anupper casing portion 12 a and a lower casing portion 12 b, as shown inFIG. 11. The upper casing portion 12 a and the lower casing portion 12 bare configured to be connected together when assembling the battery jumpstarting device 10.

The battery jump starting device 10 further comprises the batteryconnection device 100 and controller assembly 210 both disposed withinthe casing 12. The controller assembly 210 comprises a circuit board 212located adjacent to another circuit board 214.

The positive terminal of the battery assembly 110 (FIG. 12) is connectedto the circuit board 212 via a positive power wire 216. For example, thepositive power wire 216 is soldered to the positive conductor bar 114(FIG. 5). The negative terminal of the battery assembly 110 is connectedto the circuit board 214 via a negative power wire 218.

The relay circuit board 136 is provided with a wire set 220 having aconnector 222. The connector 222 is configured to connect with the relayboard connector 224 located on the circuit board 212 of the controllerassembly 210 during assembly of the battery jump starting device 10.

The battery assembly 110 further comprises a wire set 226 having aconnector 228. The connector 228 is configured to connect with thebattery cell charging/monitoring connector 230 located on the circuitboard 212 of the controller assembly 220.

The battery assembly 110 also comprises a battery temperature sensorhaving a wire set 232 having a connector 234. The connector 234 isconfigured to connect with the temperature sensor connector 236 locatedon the circuit board 212 of the controller assembly 220.

The circuit board 212 is provided with in charge power resistors 240 andan out relay 242, as shown in FIG. 11. Further, the lower casing portion12 a is provided with a main user out connector 244 having a wire set246 connected to the circuit board 214, and a main user in connector 248having a wire set 250 connected to the circuit board 214.

The battery assembly 110 is connected to battery jump starting device10, as shown in FIG. 11. The battery connector device 110 is installedwithin the casing 12 of the battery jump starting device 10 whenassembled.

Enhanced Conductivity

An enhanced conductivity battery connector device 400 is shown in FIGS.13-25. The enhanced conductivity battery connector device 400 provides asignificantly increased conductivity compared to the battery connectordevice 100, as shown in FIGS. 5-10.

The amount of power to be conducted from the battery 412 to the clampscan be enhanced as follows:

1) Increase Wire Gauge

-   -   e.g. change 4 AWG (American Wire Gage) positive cable 18 and        negative cable 22 (FIG. 9) to a 2 AWG positive cable 318 and        negative cable 322 (FIGS. 13 and 15).

2) Increase Conductivity of Negative Cable Connection

e.g. negative cable end 322 a (FIG. 15) connection to the relays willextend all the way across the connector pins 422 c of the relays 422.

3) Increase Conductivity of Positive Cable Connection

e.g. the positive battery tab 414 is lengthened so that the positivecable 318 can be rolled up (FIGS. 17-22) in the positive battery tab 414and soldered together thoroughly:

4) Increase Conductivity of Diode Connection

-   -   e.g. replace the diode connection 150 (FIG. 5 with the diode        connection 450 (FIG. 23).

5) Redesign Resistor/Diode Printed Circuit Board (PCB)

-   -   e.g. replace the diode printed circuit board (PCB) 152 (FIG. 10)        with the diode printed circuit board (PCB) 452 (FIG. 23).

6) Reconnect Resistors

-   -   e.g. reconnect resistors R134A&B, R135A&B located on the diode        printed circuit board (PCB) 152 (FIG. 10) to be connected again.

A detailed description of each of these enhanced conductivity featuresor arrangement is set forth below.

1) Increase Wire Gauge

The gauge of the positive cable 18 and negative cable 22 (FIG. 9) forexample, can be increased from 4 AWG (American Wire Gage) cable to a 2AWG cable for positive cable 318 and negative cable 322 (FIGS. 13 and15). The comparative specifications of the 4 AWG cable and 2 AWG cableare as follows

2AWG 4AWG Diameter 0.2576 in 0.2294 in (6.544 mm) (5.189 mm) Turns ofwire 3.88/in  4.89/in  (1.53/cm) (1.93/cm) Area 66.4 kcmil 41.7 kcmil(33.6 mm²) (21.2 mm²) Resistance/length 0.5127 mΩ/m 0.8152 mΩ/m (0.1563mΩ/ft) (0.2485 mΩ/m) Ampacity 95 (60° C.) 70 (60° C.) 115 (75° C.) 85(75° C.) 130 (90° C.) 95 (90° C.) Fusing current 1.3 kA (10 s) 946 A (10s) 10.2 kA (1 s) 6.4 kA (1 s) 57 kA (32 ms) 36 kA (32 ms)

The 2 AWG cable provides a significant increase of conductivity (i.e.ampacity) compared to the 4 AWG cable (i.e. approximately 36%).

2) Increase Conductivity of Negative Cable Connection

The negative cable 322 (FIG. 15) can be connected to the battery 412(FIG. 13) in a manner to increase the conductivity (i.e. ampacity)between the battery 412 and negative cable 322. For example, thenegative cable end 322 a can be directly connected (e.g. soldered) tothe connector prongs 442 c (FIG. 15) of the relays 442. Specifically,the negative cable end 322 a can extend across and directly connect toall relays 342 of the smart switch battery interface 434, as shown inFIGS. 14 and 15. Further, the negative cable end 322 a can be connectedto a conductor loop 441 of the circuit board conductor bar 440.

The negative cable 322, for example, can be stranded wire comprising aninner electrical wire conductor 322 b composed of an untwisted ortwisted bundle of wires 322 d disposed within an outer electricalinsulating sheath 322 c. The electrical insulating sheath 322 c of thenegative cable 322 can be removed from the negative cable end 322 aexposing the inner electrical conductor 322 b at the negative cable end322 a.

The exposed bundle of wires 322 d of the electrical conductor 322 b canbe forced over the ends of the exposed connector pins 442 c of therelays 442 so that strands of wires 322 d are captured between theadjacent connector pins 442 c. The exposed bundles of wires 332 d can befurther forced into contact with the conductor bar 440 (e.g. made ofcopper). Solder 423 is applied to this assembly so that the solder flowsbetween the exposed bundles of wires 422 d to the connector pins 442 cand the conductor bar 440 to complete the electrical connection betweenthe negative cable 322 and the smart switch battery interface 434connected to the battery 412.

The length of the exposed bundle of wires 322 d is selected so thatexposed bundle of wires 322 d directly connects with each set ofconnector pins 442 c of each and every relay 442 to provide the maximumelectrical conductivity (i.e. maximum ampacity) between the negativecable 322 and the battery 412.

3) Increase Conductivity of Positive Cable Connection

The positive cable 318 can be connected to the battery 412 in a mannerto increase the conductivity (i.e. ampacity) between the battery 412 andpositive cable 318. For example, the positive cable 318 can be rolled upin the positive battery tab 414 and soldered together thoroughly. Theconnection between the positive cable 318 and battery 412 is shown inFIGS. 16-22.

The positive cable 318, for example, can be stranded wire comprising aninner electrical wire conductor 318 b composed of an untwisted ortwisted bundle of wires 318 d disposed within an outer electricalinsulating sheath 318 c. The electrical insulating sheath 318 c of thepositive cable 318 can be removed from the positive cable end 318 aexposing the inner electrical conductor 318 b at the positive cable end318 a.

The battery 412 is provided with a positive battery tab 414. Thepositive battery tab 414 is a metal sheet (e.g. copper sheet) connectedto the positive terminal tab 414 of the battery 412.

The exposed bundle of wires 318 d of the inner electrical conductor 318b can be soldered with tin, and then rolled up within the positivebattery tab 312 a. Solder 415 (FIG. 21) is applied to the exposed bundleof wires 318 d and the positive battery tab 312 a.

The length of the exposed bundle of wires 318 d is selected so thatexposed bundle of wires 318 d directly connects with the full width ofthe positive battery tab 414 to provide the maximum electricalconductivity (i.e. maximum ampacity) between the battery 312 and thepositive cable 318.

4) Increase Conductivity of Diode Connection

The positive cable 318 can be provided with a diode connection 450configured to increase the conductivity along the positive cable 318, asshown in FIGS. 23-25.

The diode connection 450 comprises a plurality of diodes 454 connectedbetween positive cable sections 318 e and 318 f (FIG. 25) For example,the diode connection 450 comprises six (6) back-charge type diodes (e.g.Schottky barrier diodes).

The diodes 454 are soldered between the positive cable sections 318 eand 318 f. Specifically, the diode conductor tabs 454 a are soldered tothe positive cable section 318 e and the diode conductor prongs 454 bare soldered to the positive cable section 318 f. More specifically, thediode conductor prongs 454 b of the diodes 354 extend through the diodecircuit board 452, extend into the bundle of wires 318 b, and then aresoldered in place completing assembly of the diode connection 450.

The diode connection 450 is then insulated, for example, using a shrinkwrap insulator 455 (FIG. 25), which is applied around the diodeconnection 450, and then shrunk by applying heat (e.g. using heat gun).

5) Redesign Resistor/Diode Printed Circuit Board (PCB)

e.g. redesign of resistor/diode PCB to eliminate the diodes extendingtherefrom;

6) Reconnect Resistors

-   -   e.g. reconnect resistors R134A&B, R135A&B that are on the        Resistor/Diode PCB to be connected again.

TEST #1

The battery connection device 100 shown in FIG. 5 was subjected to a1250A Load Test. The results are shown in FIG. 27, and as follows:

Pulse #1 Average Power of 4799.01 W

Pulse #2 Average Power of 5528.99 W

Pulse #3 Average Power of 6101.63 W

TEST #2

The battery connection device 400 shown in FIG. 13 was subjected to a1250A Load Test. The results are shown in FIG. 28, and as follows:

Pulse #1 Average Power of 6584.61 W

Pulse #2 Average Power of 7149.60 W

Pulse #3 Average Power of 7325.91 W

This results in a significant increase of approximately twenty percent(20%) for peak power compared to the results of TEST #1.

Another enhanced conductivity battery conductor device 500 is shown inFIGS. 29-37. The enhanced conductivity battery connector device 500provides a significantly increased conductivity compared to the batteryconnector device 100, as shown in FIGS. 5-10.

The battery conductor device 500 comprises the battery assembly 410,including the battery 512 connected to the positive cable 518 and thenegative terminal conductor plate 530. A positive wire 519 is connecteddirectly or indirectly to the positive tab or positive cable 518 of thebattery 530, and a negative wire 523 is connected directly or indirectlyto the negative tab or negative terminal conductor plate 530. Thebattery conductor device 500 can further include a bundle of wires 570connected to or associated with the operation of the battery 512 (e.g.battery temperature sensor, power supply, etc.).

The battery 512 can comprise a single battery cell 512 c (FIG. 30), ormultiple battery cells 512C connected end-to-end in series. Three (3)separate battery cells 512 c are shown in FIG. 30.

The battery cells 512 c each have positive and negative tabs 512 dlocated at opposite ends of each battery cell 512 c. The battery cells512 c are connected together in series by welding (e.g. sonically and/orthermally welding) and/or soldering respective positive and negativetabs 512 d together. For example, the tabs 512 d are positioned so as tooverlap each other (e.g. edges overlapping opposite tab 512 d, oredge-to-edge).

The tabs 512 d are metal plates (e.g. relative thin metal foils)extending outwardly from the body and opposite edges of each batterycell 512 c. As shown in FIG. 30, the tabs 512 d extend along oppositeedges at the width of each battery cell 512 c. The tabs 512 d are eachcentered and extend most of the width of each opposite edge of eachbattery cell 512 c.

As shown in FIGS. 30 and 31, a separate tab 512 e is added or connectedto the right side of the battery cell 512 c to extend the length of thetab 512 d. The separate tab 512 e is shown as having the same width asthe tab 512 d; however, this width can be different. To assemble theseparate tab 512 e to the tab 512 d, for example, the separate tab 512 eis positioned to overlap over the tab 512 d, and then welded (e.g.sonically and/or thermally welded) and/or soldered together. The exposedend of the positive cable 518 is then wound up inside the separate tab,as shown in FIGS. 32 and 34. For example, the initially flat separatetab 512 e is wrapped around the exposed end of the positive cable 518,and then connected to the exposed end by welding (e.g. sonically and/orthermally welding) and/or soldering. For example, a layer of solder isapplied to one or both sides of the separate tab 512 e, and then afterwrapping the separate tab 512 e around the exposed end of the positivewire 518, the assembly is heated to melt the layered solder and solderthe assembly together.

The three (3) battery cells 512 c once connected together, as shown inFIG. 32, are then folded over each other into the layered battery cellarrangement shown in FIG. 33. The layered battery cell arrangement canbe packaged (e.g. the three (3) battery cells can be taped or shrinkwrapped together), or placed within a battery cover or casing, as shownin FIG. 34.

As shown in FIG. 35, the negative tab 512 d can be attached to thenegative terminal conductor plate 530. For example, the negative tab 512d can be wrapped partially or fully, as shown, around the negativeterminal conductor plate 530. The negative tab 512 d can be providedwith a plurality of through holes 512 f to facilitate welding and/orsoldering the negative tab 512 d to the negative terminal conductorplate 530. For example, the through holes 512 f can be square-shapedthrough holes arranged into a matrix, as shown in FIG. 35. The negativewire 523 is shown connected (e.g. soldered) to the negative tab 512 d

A separate tab 512 e (see FIG. 30) can be connected to the negative tab512 d to lengthen same, so that the lengthened negative tab can bewrapped or wound around the negative terminal conductor plate 530 morethan one time (e.g. 2, 3, 4, or more times). In this manner, theelectrical connection between the negative tab 512 d and the negativeterminal conductor plate 530 can be enhanced. The separate tab 512 e canbe provided with a layer of solder on one or both sides, so that afterthe separate tab 512 e is wrapped or wound around the negative terminalconductor plate 530, this assembly can be heated up to solder theseparate tab 512 e onto the negative terminal conductor plate 530.

The completed assembly of the battery conductor device 500 with theconnected separate positive tab 512 d ready to be wrapped or wound anexposed end of the positive cable 518 (FIG. 29) can be seen in FIG. 36.The bundle of wires 570 shown in FIG. 36, includes wires 572 for atemperature sensor embedded within the battery 512 (e.g. temperaturesensor located near battery tab or between battery cells. Thetemperature sensor 574 having two (2) wires 572 a, 572 b is shown inFIG. 37.

The battery conductor device 500 can comprise a diode connector 550connected inline or splice into the positive cable 518, as shown in FIG.38.

The battery conductor device 500 comprises a diode circuit board 552having a plurality of diodes 454 assembled thereon. The diodes 454 eachhave a diode conductor tab 454 a connected (e.g. soldered) to an exposedend of the positive cable 518. The prongs of the diodes 454 extendthrough holes in the diode circuit board 552, and are soldered to boththe conductive traces and exposed end of the positive cable 518 alongwith a resistor 576 to complete the assembly.

1. A rechargeable battery device for use in a battery jump startingdevice, the device comprising: a rechargeable battery comprising atleast one battery cell having a positive tab and a negative tab; apositive cable having a conductor connected to the positive tab of theat least one battery cell of the rechargeable battery; and a negativeterminal conductor bar connected to the negative tab of the at least onecell of the rechargeable battery.
 2. (canceled)
 3. (canceled)
 4. Thedevice according to claim 1, further comprising a separate tab connectedto the positive tab of the at least one cell of the rechargeable batteryto extend a length of the positive tab of the at least one cell of therechargeable battery.
 5. The device according to claim 4, wherein theseparate tab connected to the positive tab of the at least one batterycell of the rechargeable battery wraps around and connects to aconductor of the positive cable.
 6. The device according to claim 1,wherein the positive tab wraps around and connects to the conductor ofthe positive cable.
 7. The device according to claim 1, wherein thenegative tab wraps around the the negative conductor bar to electricallyconnect the at least one battery cell of the rechargeable battery to thenegative conductor bar.
 8. The device according to claim 6, wherein theconductor of the positive cable is soldered to the positive tab of theat least one battery cell of the rechargeable battery and the negativeterminal conductor bar is soldered to the negative tab of the at leastone battery cell of the rechargeable battery.
 9. The device according toclaim 1, wherein the rechargeable battery is rectangular-shaped, and thenegative terminal conductor bar is L-shaped and wraps around arespective corner of the rechargeable battery.
 10. The device accordingto claim 9, wherein the positive tab and the negative tab of the atleast one battery cell of the rechargeable battery extend from oppositesides of the rechargeable battery.
 11. The device according to claim 1,wherein the positive tab and negative tab of the at least one batterycell of the rechargeable battery extend along opposite edges along awidth of the at least one battery cell of the rechargeable battery. 12.The device according to claim 4, wherein the the separate tab has a samewidth as the positive tab of the at least one battery cell of therechargeable battery.
 13. The device according to claim 4, wherein theseparate tab overlaps the positive tab of the at least one battery cellof the rechargeable battery.
 14. The device according to claim 4,wherein the conductor of the positive cable is wound up inside theseparate tab.
 15. The device according to claim 1, further comprisinganother separate tab connected to the negative tab of the at least onecell of the rechargeable battery to extend a length of the negative tabof the at least one cell of the rechargeable battery.
 16. The deviceaccording to claim 15, wherein the another separate tab wraps more thanone time around the negative conductor bar to enhance the electricalconnection between the negative conductor bar and the negative tab ofthe at least one battery cell of the rechargeable battery. 17.(canceled)
 18. (canceled)
 19. A jump starting device having a smartswitch controller, the jump starting device comprising: a rechargeablebattery device according to claim 1; a positive clamp connected to thepositive cable of the rechargeable battery assembly device; a smartswitch interface connected to and controlled by the smart switchcontroller, the smart switch interface comprising a circuit board havinga first circuit board conductor bar connected to the negative terminalconductor bar of the rechargeable battery assembly and a second circuitboard conductor spaced apart from the first circuit board conductor baron the circuit board, the smart switch interface further comprising oneor more relays connected between the first circuit board conductor barand the second circuit board conductor bar for providing isolationbetween the negative terminal of the rechargeable battery and a batterybeing jump started by the battery jump starting device; a negative cableconnected to the second circuit board conductor bar of the smart switchinterface; and a negative clamp connected to the negative cable.
 20. Thedevice according to claim 19, further comprising a separate tabconnected to the positive tab of the at least one cell of therechargeable battery to extend a length of the positive tab of the atleast one cell of the rechargeable battery.
 21. The device according toclaim 20, wherein the separate tab connected to the positive tab of theat least one battery cell of the rechargeable battery wraps around andconnects to a conductor of the positive cable.
 22. The device accordingto claim 19, wherein the positive tab wraps around and connects to theconductor of the positive cable.
 23. The device according to claim 19,wherein the negative conductor bar to electrically connect the at leastone battery cell of the rechargeable battery to the negative conductorbar.
 24. The device according to claim 22, wherein the conductor of thepositive cable is soldered to the positive tab of the at least onebattery cell of the rechargeable battery and the negative terminalconductor bar is soldered to the negative tab of the at least onebattery cell of the rechargeable battery.